Method of laying carpet to avoid seam peaking and apparatus therefor

Abstract

A method of laying carpet to avoid seam peaking, the method employing an enhanced width seaming tape spanning the abutting edges of the carpet forming the seam. The tape has a hot melt adhesive on the upper surface facing the carpet backing. An enhanced width carpet seaming iron is employed to melt the adhesive and to provide a bond between the tape and the carpet backing. In an alternative embodiment, the tape is made in three segments with one of them applied spanning the seam and the other two in flanking positions along either side of the seam spanning tape. In another embodiment the seaming tape is constructed with a composite modulus of elasticity which varies across the width of the tape. The invention also includes several embodiments of the enhanced width seaming iron for application of the tape to the carpet seam.

What is claimed is: 
     
       1. A method for laying multiple layer, tufted carpet to substantially reduce seam peaking which tends to occur in such carpeting after abutting edges of the carpet are secured together by means of hot-melt adhesive coated normal seaming tape normally having a width of approximately three inches and the carpet is finally stretched, said method comprising the steps of: cutting and fitting the carpet to the floor area with two abutting carpet edges forming a carpet seam;   laying a hot-melt adhesive coated enhanced width seaming tape beneath said carpet seam, said enhanced width seaming tape being configured with its composite modulus of elasticity varying laterally across its width, said enhanced width seaming tape having a width of approximately twice the width of said normal seaming tape, said enhanced width seaming tape underlying the carpet sections substantially equally on either side of said seam, there being meltable adhesive on the side of said enhanced width seaming tape facing upward and engaging the carpet at said carpet seam;   heating the adhesive on said enhanced width seaming tape with a carpet seaming iron of a width sufficient to simultaneously heat the full width of said enhanced width seaming tape to make the adhesive molten;   forcing the adjacent carpet edges down onto the molten adhesive side of said enhanced width seaming tape; and   then stretching the carpet to the floor periphery in conventional manner.   
     
     
       2. The method recited in claim 1, wherein said enhanced width seaming tape comprises a substrate, a layer of hot-melt adhesive and a layer of fibers known as scrim forming a predetermined pattern on said adhesive layer. 
     
     
       3. The method recited in claim 2, wherein said scrim is so arranged on said enhanced width seaming tape that a central longitudinal portion of said enhanced width seaming tape has a first modulus of elasticity and flanking longitudinal margin areas have a second modulus of elasticity different from the first modulus. 
     
     
       4. The method recited in claim 3, wherein said second modulus of elasticity is less than said first modulus. 
     
     
       5. The method recited in claim 3, wherein the width of said central portion is approximately double the width of either said flanking margin area. 
     
     
       6. The method recited in claim 3, and further comprising second flanking longitudinal margin areas having a third modulus of elasticity. 
     
     
       7. The method recited in claim 6, wherein the third modulus of elasticity is less than the second modulus which is in turn less than the first modulus. 
     
     
       8. The method recited in claim 3, wherein said scrim is formed with approximately twice as many scrim fibers in said central portion as are in said flanking margin areas. 
     
     
       9. The method recited in claim 8, wherein said scrim fibers are formed in a continuous lateral zig-zag pattern throughout the length of said enhanced width seaming tape. 
     
     
       10. The method recited in claim 8, wherein said scrim fibers are formed with one continuous zig-zag pattern in said central portion and a different zig-zag pattern in said flanking margin areas. 
     
     
       11. The method recited in claim 8, wherein said scrim fibers are formed with one continuous zig-zag pattern in said central portion and straight, spaced fibers extending from one flanking margin area to the other. 
     
     
       12. The method recited in claim 8, wherein said scrim fibers are formed as straight segments of varying length arranged laterally across said enhanced width seaming tape. 
     
     
       13. A method of laying multiple layer, tufted carpet to substantially reduce seam peaking which tends to occur in such carpeting after abutting edges of the carpet are secured together by means of hot-melt adhesive coated normal seaming tape normally having a width of approximately three inches and the carpet is finally stretched, said method resulting in a flat carpet seam and comprising the steps of: cutting and fitting the carpet to the floor area with abutting carpet edges forming seams in conventional manner;   laying a hot-melt adhesive coated enhanced width seaming tape beneath each said carpet seam, said enhanced width seaming tape having a width of approximately twice the width of said normal seaming tape and underlying the carpet sections substantially equally on either side of a respective said seam, there being meltable adhesive on the side of said enhanced width seaming tape facing upward and engaging the carpet at the respective said carpet seam;   heating the enhanced width seaming tape with a carpet seaming iron of a width sufficient to simultaneously heat the full width of the adhesive of said enhanced width seaming tape to make the adhesive molten;   forcing the adjacent carpet edges down onto the molten adhesive side of said enhanced width seaming tape; and   then stretching the carpet to the floor periphery in conventional manner.   
     
     
       14. A method of laying multiple layer, tufted carpet to substantially reduce seam peaking which tends to occur in such carpeting after abutting edges of the carpet are secured together by means of hot-melt adhesive coated seaming tape normally having a width of approximately three inches and the carpet is finally stretched, said method resulting in a flat carpet seam and comprising the steps of: cutting and fitting the carpet to the floor area with abutting carpet edges forming seams in conventional manner;   laying a hot-melt adhesive coated enhanced width seaming tape beneath each said carpet seam, said enhanced width seaming tape having a width of about six inches and underlying the carpet sections substantially equally on either side of a respective said seam, there being meltable adhesive on the side of said enhanced width seaming tape facing upward and engaging the carpet at the respective said carpet seam;   heating the enhanced width seaming tape with a carpet seaming iron of a width sufficient to simultaneously heat the full width of the adhesive of said enhanced width seaming tape to make the adhesive molten;   forcing the adjacent carpet edges down onto the molten adhesive side of said enhanced width seaming tape; and   then stretching the carpet to the floor periphery in conventional manner.